Remove/install crankshaft · ar0320w4351b · Mercedes-Benz WIS

AR03.20-W-4351B

Remove/install crankshaft

23.9.10

ENGINES 541.9 in MODEL 950, 952, 953, 954

ENGINES 542.9 in MODEL 950, 952, 954

W03.20-0017-06

Shown on engine 541.9

1 Crankshaft

2 Main bearing shell

3 Main bearing shell

4 Thrust plate fitted bearing

5 Main bearing cap

6 Main fitted bearing cap

7 Main bearing cap central bolt

8 Side bolt of main bearing cap

9 Crankshaft sprocket

L Shank length

W03.20-1099-09

Shown on engine 541.9

1 Crankshaft

2 Main bearing shell

3 Main bearing shell

4 Thrust plate fitted bearing

11  Drift

Arrows Markings

5 Main bearing cap

6 Main fitted bearing cap

9 Crankshaft sprocket

10 Camshaft sprocket

Modification notes

23.6.10

Work procedure changed.

	Removing
1	Remove engine		AR01.10-W-2400B
2	Remove MR/PLD control unit		AR07.15-W-1628B
3	Remove timing case		AR01.60-W-8200B
4	Remove oil pump		AR18.10-W-6020B
5	Remove front housing cover		AR01.40-W-8800B
6	Remove pistons		AR03.10-W-7021B
7	Remove main bearing cap (5) and main fitted bearing cap (6)	 Check identification of the main bearing cap (5) and mark if necessary.
8	Remove main bearing shells (3) from main bearing caps (5) and from main fitted bearing cap (6)	 Identify main bearing shells (3) to respective main bearing cap (5) and to main fitted bearing cap (6).
9	Remove fitted bearing thrust plates (4) from main fitted bearing cap (6)
10	Push fitted bearing thrust plates (4) at fitted bearing of crankshaft (1) out of crankcase
11	Lift crankshaft (1) out of crankcase using a lifting cradle and place down to one side	  Screw drifts (11) into crankshaft (1) at front and rear and secure shackle on it.
		 Drift	*403589026300
12	Remove main bearing shells (2) from crankcase	 Mark main bearing shells (2) relative to the crankcase.
13	Clean crankshaft (1) and oil duct in crankshaft (1)
	Check
14	Check grooved pins for fitted bearing thrust plates (4) at main fitted bearing cap (6)	 If grooved pins are damaged: 
		Replace grooved pin at main fitted bearing cap.	AR01.40-W-8600-01G
		Protrusion of grooved pin to main bearing cap	*BE01.40-N-1003-02C
15	Check crankshaft (1) by means of visual inspection for damage and cracks	 If there is damage or cracks: 
		Replace crankshaft (1).
16	Clean main bearing shells (2, 3), fitted bearing thrust plates (4), main bearing journals of crankshaft (1) using chamois leather and check by means of visual inspection
	Information on assessing wear of main bearings and main bearing journals		AH03.20-N-1000-02A
17	Measure concentricity of crankshaft (1) at middle main bearing journal	 On engine 541.9, measure at both center main bearing journals. On engine 542.9, measure at center main bearing journal.	AR03.20-W-4351-08G
			*BE03.20-N-1007-02C
		Dial gage	*001589532100
		Dial gauge holder	*363589022100
18	Inspect hardness of main and connecting rod bearing journals		AR03.20-W-4351-09G
		Hardness of main bearing and connecting rod journals	*BE03.20-N-1009-02C
		Hardness tester	*000589202100
	Notes on hardness test		AH00.00-N-0012-01A
19	Determine crankshaft bearing radial play		AR03.20-W-4291-02B
		Main bearing cap central bolt	*BE01.40-N-1002-02C
		Main bearing journal dia. main bearing journal width (except main bearing fitted bearing journal)	*BE03.20-N-1001-02C
		Main bearing journal dia. fitted bearing journal width	*BE03.20-N-1002-02C
		Crankshaft main bearing inside dia. when installed	*BE03.20-N-1012-02C
		Main bearing radial play	*BE03.20-N-1015-02C
		 Central bolt for main bearing cap	*BA01.40-N-1013-01D
		 Side bolt for main bearing cap	*BA01.40-N-1016-01D
		 Dial indicator	*001589532100
20	Determine connecting rod bearing radial play		AR03.20-W-4291-04A
		Connecting rod bearing inside dia. for connecting rod bearing shells inserted	*BE03.10-N-1001-01C
		Bolt of connecting rod bearing cap to connecting rod	*BE03.10-N-1005-01C
		Connecting rod bearing radial play	*BE03.10-N-1006-01C
		Connecting rod journal diameter, connecting rod journal width	*BE03.20-N-1004-02C
			*BA03.10-N-1001-01C
		 Dial indicator	*001589532100
21	Determine thickness of fitted bearing thrust plate (4) at crankshaft (1)		AR03.20-W-4351-01G
		Main bearing journal dia. fitted bearing journal width	*BE03.20-N-1002-02C
		Wall thickness of fitted bearing thrust plates	*BE03.20-N-1013-02C
		 Dial indicator	*001589532100
22	Measure central bolts of main bearing cap (7)	 If permissible shank length (L) is exceeded: 	*BE01.40-N-1002-02C
		Replace respective central bolt of main bearing cap (7).
	Install
23	Remove metal dust from the internal components	 Only if bearing damage occurred: 
		Remove potential metal dust from oil ducts and clean internal components.
24	Insert main bearing shells (2) with groove into crankcase	 The oil holes of the main bearing shells (2) must match with the oil holes in the crankcase, otherwise damage to the bearing may occur.
		 Observe identification of main bearing shells (2) to crankcase. Lubricate contact surfaces of main bearing shells (2) with engine oil.
25	Put crankshaft (1) with shackle onto main bearing shells (2) in crankcase	 Markings (arrows) on crankshaft gear (9) and camshaft sprocket (10) must be positioned opposite each other. Screw in second  drift (11) or second bolt into one of the threaded holes in crankshaft (1), if necessary, and turn crankshaft (1) using a suitable lever.
		 Drift	*403589026300
26	Remove drift (11) and shackle from crankshaft (1)
27	Insert fitted bearing thrust plates (4) between crankshaft (1) and crankcase	 Lubricate fitted bearing thrust plates (4) with engine oil. Grooves in fitted bearing thrust plates (4) must point towards the crank webs.
28	Insert main bearing shells (3) into main bearing cap (5) and main fitted bearing cap (6)	 Lubricate contact surfaces of main bearing shells (3) with engine oil. Observe identification of the main bearing shells (3) to respective main bearing cap (5) and to main fitted bearing cap (6). Retaining lug at main bearing shell (3) must be inserted into groove provided for this purpose.
29	Attach fitted bearing thrust plates (4) to main fitted bearing cap (6)	 Lubricate fitted bearing thrust plates (4) with engine oil. Grooves in fitted bearing thrust plates (4) must point towards the crank webs. Fitted bearing thrust plates (4) are fixed in place via bores at the dowel pins at main fitted bearing cap (6).
30	Install main bearing cap (5) and main fitted bearing cap (6) with fitted bearing thrust plates (4)	 Main bearing cap (5) and main fitted bearing cap (6) have dowel pins and are marked with numbers and must be installed according to numbers (e.g. 1x xxx), beginning at the front, in an ascending order.
31	Lubricate central bolt of main bearing cap (7) and side bolt of main bearing cap (8) with engine oil
32	Tighten main bearing cap (5) and main fitted bearing cap (6)	 First tighten central bolts of main bearing cap (7) and then tighten side bolts of main bearing cap (8).
		 Central bolt for main bearing cap	*BA01.40-N-1013-01D
		 Side bolt for main bearing cap	*BA01.40-N-1016-01D
33	Rotate crankshaft (1) by hand and check for unobstructed movement.
34	Determine crankshaft bearing crankshaft end play (1)		AR03.20-W-4291-03G
		Axial play	*BE03.20-N-1006-02C
		 Dial indicator	*001589532100
		 Dial indicator holder	*363589022100
35	Perform additional checking work for engine repair on crankshaft (1)		AR03.20-W-0002A
36	Install pistons		AR03.10-W-7021B
37	Install front housing cover		AR01.40-W-8800B
38	Install oil pump		AR18.10-W-6020B
39	Install timing case		AR01.60-W-8200B
40	Install MR/PLD control unit		AR07.15-W-1628B
41	Install engine		AR01.10-W-2400B

Check values for crankcase

Number	Designation			Engine 541.9, 542.9


BE01.40-N-1002-02C	Main bearing cap central bolt	Thread diameter	M	18
		Length of shank when new	mm	173
		Permissible shank length	mm	176
BE01.40-N-1003-02C	Protrusion of grooved pin to main bearing cap		mm	4.5 to 4.7

Check values for connecting rod

Number	Designation			Engine 541.9, 542.9 up to engine end no. 054765


BE03.10-N-1001-01C	Connecting rod bearing inner diameter for connecting rod bearing shells inserted	Default	mm	94.054 to 94.096
		Deviation 0.10	mm	93.954 to 93.996
		Deviation 0.25	mm	93.804 to 93.846
		Deviation 0.50	mm	93.554 to 93.596
		Deviation 0.75	mm	93.304 to 93.346
		Deviation 1.00	mm	93.054 to 93.096
BE03.10-N-1005-01C	Bolt, connecting rod bearing cap to connecting rod	Thread diameter	M	161.5
		Permissible shank length	mm	74.5
BE03.10-N-1006-01C	Connecting rod bearing radial play		mm	0.064 to 0.126

Check values for connecting rod

Number	Designation			Engine 541.9, from engine end no. 054766	Engine 542.9 from engine end no. 054766


BE03.10-N-1001-01C	Connecting rod bearing inner diameter for connecting rod bearing shells inserted	Default	mm	94.064 to 94.110	94.064 to 94.110
		Deviation 0.10	mm	93.964 to 94.010	93.964 to 94.010
		Deviation 0.25	mm	93.814 to 93.860	93.814 to 93.860
		Deviation 0.50	mm	93.564 to 93.610	93.564 to 93.610
		Deviation 0.75	mm	93.314 to 93.360	93.314 to 93.360
		Deviation 1.00	mm	93.064 to 93.110	93.064 to 93.110
BE03.10-N-1005-01C	Bolt of connecting rod bearing cap to connecting rod	Thread diameter	M	161.5	161.5
		Permissible shank length	mm	74.5	74.5
BE03.10-N-1006-01C	Connecting rod bearing radial play		mm	0.064 to 0.126	0.064 to 0.126

Test specifications for crankshaft

Number	Designation			Engine 541.9 EURO standard Ⅱ up to engine no. 098131	Engine 542.9 EURO standardⅡ Up to engine no. 098131


BE03.20-N-1001-02C	Main bearing journal dia. main bearing journal width (except main bearing fitted bearing journal)	Standard dia. Width	mm mm	107.980 - 108.000 42.000 - 42.160	107.980 - 108.000 42.000 - 42.160
		Dia. deviation 0.10 Width	mm mm	107.880 - 107.900 42.000 - 42.160	107.880 - 107.900 42.000 - 42.160
		Dia. deviation 0.25 Width	mm mm	107.730 - 107.750 42.000 - 42.160	107.730 - 107.750 42.000 - 42.160
		Dia. deviation 0.50 Width	mm mm	107.480 - 107.500 42.000 - 42.160	107.480 - 107.500 42.000 - 42.160
		Dia. deviation 0.75 Width	mm mm	107.230 - 107.250 42.000 - 42.160	107.230 - 107.250 42.000 - 42.160
		Dia. deviation 1.00 Width	mm mm	106.98 - 107.000 42.000 - 42.160	106.98 - 107.000 42.000 - 42.160
BE03.20-N-1002-02C	Main bearing journal dia. fitted bearing journal width	Dia. standard width standard	mm mm	107.980 - 108.000 42.000 - 42.062	107.980 - 108.000 42.000 - 42.062
		Dia. deviation 0.10 width standard	mm mm	107.880 - 107.900 42.000 - 42.062	107.880 - 107.900 42.000 - 42.062
		Dia. deviation 0.25 width deviation 0.50	mm mm	107.730 - 107.750 42.500 - 42.562	107.730 - 107.750 42.500 - 42.562
		Dia. deviation 0.50 width deviation 0.50	mm mm	107.480 - 107.500 42.500 - 42.562	107.480 - 107.500 42.500 - 42.562
		Dia. deviation 0.75 width deviation 1.00	mm mm	107.230 - 107.250 43.000 - 43.062	107.230 - 107.250 43.000 - 43.062
		Dia. deviation 1.00 width deviation 1.00	mm mm	106.98 - 107.000 43.000 - 43.062	106.98 - 107.000 43.000 - 43.062
BE03.20-N-1004-02C	Connecting rod journal diameter. connecting rod journal width	Standard dia. Width	mm mm	93.980...94.000 37.000...37.100	93.980 - 94.000 81.000 - 81.140
		Dia. deviation 0.10 Width	mm mm	93.880 - 93.900 37.000 - 37.100	93.880 - 93.900 81.000 - 81.140
		Dia. deviation 0.25 Width	mm mm	93.730 - 93.750 37.000 - 37.100	93.730 - 93.750 81.000 - 81.140
		Dia. deviation 0.50 Width	mm mm	93.480 - 93.500 37.000 - 37.100	93.480 - 93.500 81.000 - 81.140
		Dia. deviation 0.75 Width	mm mm	93.230 - 93.250 37.000 - 37.100	93.230 - 93.250 81.000 - 81.140
		Dia. deviation 1.00 Width	mm mm	92.980 - 93.000 37.000 - 37.100	92.980 - 93.000 81.000 - 81.140
BE03.20-N-1006-02C	Main bearing axial play		mm	0.150 to 0.351	0.150 to 0.351
BE03.20-N-1007-02C	Variation in concentricity measured at middle main bearing journal (mounted at outer main bearing journals)		mm	0.06	0.06
BE03.20-N-1009-02C	Hardness of main bearing and connecting rod bearing journals (Rockwell hardness)		HRC	53 to 59	53 to 59
BE03.20-N-1012-02C	Crankshaft main bearing inner dia. when installed	Default	mm	108.056 to 108.102	108.056 to 108.102
		Deviation 0.10	mm	107.956 to 108.002	107.956 to 108.002
		Deviation 0.25	mm	107.806 to 107.852	107.806 to 107.852
		Deviation 0.50	mm	107.556 to 107.602	107.556 to 107.602
		Deviation 0.75	mm	107.306 to 107.352	107.306 to 107.352
		Deviation 1.00	mm	107.056 to 107.102	107.056 to 107.102
BE03.20-N-1013-02C	Fit bearing - thrust washers wall thickness	Default	mm	5.375 to 5.425	5.375 to 5.425
		Deviation 0.50	mm	5.625 to 5.675	5.625 to 5.675
		Deviation 1.00	mm	5.875 to 5.925	5.875 to 5.925
BE03.20-N-1015-02C	Main bearing radial play		mm	0.077 to 0.143	0.077 to 0.143

Test specifications for crankshaft

Number	Designation			Engine 541.9 EURO standardⅡ As of engine no. 098132 Motor 541.9 Norm EURO Ⅲ	Engine 542.9 EURO standard II as of engine no. 098132 Engine 542.9 EURO standard Ⅲ


BE03.20-N-1001-02C	Main bearing journal dia. main bearing journal width (except main bearing fitted bearing journal)	Standard dia. Width	mm mm	107.980 - 108.000 42.000 - 42.160	107.980 - 108.000 42.000 - 42.160
		Dia. deviation 0.10 Width	mm mm	107.880 - 107.900 42.000 - 42.160	107.880 - 107.900 42.000 - 42.160
		dia. deviation 0.25 Width	mm mm	107.730 - 107.750 42.500 - 42.660	107.730 - 107.750 42.500 - 42.660
		Dia. deviation 0.50 Width	mm mm	107.480 - 107.500 42.500 - 42.660	107.480 - 107.500 42.500 - 42.660
		Dia. deviation 0.75 Width	mm mm	107.230 - 107.250 43.000 - 43.160	107.230 - 107.250 43.000 - 43.160
		Dia. deviation 1.00 Width	mm mm	106.980 - 107.000 43.000 - 43.160	106.980 - 107.000 43.000 - 43.160
BE03.20-N-1002-02C	Main bearing journal dia. fitted bearing journal width	Dia. standard width standard	mm mm	107.980 - 108.000 42.000 - 42.062	107.980 - 108.000 42.000 - 42.062
		Dia. deviation 0.10 width standard	mm mm	107.880 - 107.900 42.000 - 42.062	107.880 - 107.900 42.000 - 42.062
		Dia. deviation 0.25 width deviation 0.50	mm mm	107.730 - 107.750 42.500 - 42.562	107.730 - 107.750 42.500 - 42.562
		Dia. deviation 0.50 width deviation 0.50	mm mm	107.480 - 107.500 42.500 - 42.562	107.480 - 107.500 42.500 - 42.562
		Dia. deviation 0.75 width deviation 1.00	mm mm	107.230 - 107.250 43.000 - 43.062	107.230 - 107.250 43.000 - 43.062
		Dia. deviation 1.00 width deviation 1.00	mm mm	106.98 - 107.000 43.000 - 43.062	106.98 - 107.000 43.000 - 43.062
BE03.20-N-1004-02C	Connecting rod journal diameter. connecting rod journal width	Standard dia. Width	mm mm	93.980 - 94.000 37.000 - 37.130	93.980 - 94.000 81.000 - 81.140
		Dia. deviation 0.10 Width	mm mm	93.880 - 93.900 37.000 - 37.130	93.880 - 93.900 81.000 - 81.140
		dia. deviation 0.25 Width	mm mm	93.730 - 93.750 37.000 - 37.330	93.730 - 93.750 81.000 - 81.340
		Dia. deviation 0.50 Width	mm mm	93.480 - 93.500 37.000 - 37.330	93.480 - 93.500 81.000 - 81.340
		Dia. deviation 0.75 Width	mm mm	93.230 - 93.250 37.000 - 37.330	93.230 - 93.250 81.000 - 81.340
		Dia. deviation 1.00 Width	mm mm	92.980 - 93.000 37.000 - 37.330	92.980 - 93.000 81.000 - 81.340
BE03.20-N-1006-02C	Main bearing axial play		mm	0.150 to 0.351	0.150 to 0.351
BE03.20-N-1007-02C	Variation in concentricity measured at middle main bearing journal (mounted at outer main bearing journals)		mm	0.04	0.06
BE03.20-N-1009-02C	Hardness of main bearing and connecting rod bearing journals (Rockwell hardness)		HRC	51 to 61	51 to 61
BE03.20-N-1012-02C	Crankshaft main bearing inner dia. when installed	Default	mm	108.069 to 108.118	108.069 to 108.118
		Deviation 0.10	mm	107.969 to 108.018	107.969 to 108.018
		Deviation 0.25	mm	107.819 to 107.869	107.819 to 107.869
		Deviation 0.50	mm	107.569 to 107.618	107.569 to 107.618
		Deviation 0.75	mm	107.319 to 107.369	107.319 to 107.369
		Deviation 1.00	mm	107.069 to 107.118	107.069 to 107.118
BE03.20-N-1013-02C	Fit bearing - thrust washers wall thickness	Default	mm	5.375 to 5.425	5.375 to 5.425
		Deviation 0.50	mm	5.625 to 5.675	5.625 to 5.675
		Deviation 1.00	mm	5.875 to 5.925	5.875 to 5.925
BE03.20-N-1015-02C	Main bearing radial play		mm	0.077 to 0.143	0.077 to 0.143

 Cylinder crankcase, timing case cover, end cover

Number	Designation			Engine 541.9. 542.9


BA01.40-N-1013-01D	Central bolt, main bearing cap to crankcase	Stage 1	Nm	320
		Stage 2	°	90
BA01.40-N-1016-01D	Side bolt, main bearing cap to crankcase	Stage 1	Nm	120
		Stage 2	°	90

 Connecting rod

Number	Designation			Engine 541.9, 542.9


BA03.10-N-1001-01C	Bolt, connecting rod bearing cap to connecting rod	Stage 1	Nm	110
		Stage 2	°	90

363 589 02 21 00

Hardness tester

Dial indicator holder

Dial indicator

Drift

001 589 53 21 00

000 589 20 21 00

403 589 02 63 00

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